ZXR250 project.ride.break.restart build

Hi everyone
just thought I'd share my Kawasaki zxr250 story. It all begins when I was offered to buy one from a family friend (had suspected seized motor) I bought it and went about fault finding it, I found out engine was not seized and I got It running but there was a funny noise coming from the clutch area, so I decided to pull the motor out and split it and inspect, I found the noise to be coming from some grumbly bearings on the shaft that hold the clutch basket and there were a serious mission to source (found them at some import bike specialist shop in Brisbane) and fit them because you have to remove all the gears in the gearbox section to do the furthest one back, I suspect they were noisy because the timing chain must have came real loose at one stage because There's a big groove line in the rocker cover that has metal filler on top so a fair bit of metal went through the engine, anyway I did the bearings and had a general check over everything I could and put it back together and installed it back into the bike, and cranked her and it sounded amazing.
I was happy with it at that stage and went about my cosmetics repairing my fairings fiber glassing, bogging painting calipers, rims ect. I assembled everything got it rego'd and rode it for roughly 6months and really loved it, it then came into winter and would it not start in the mornings I bought a heavy cracking battery did usual check carbs, plugs, leads ect. ended up checking my valves and my intake was tiny .002" so got them shimmed to spec. and did a compression test and got over 100 in all cylinders, I was really happy and It felt amazing I thought it was quick before but after this was done it was unreal, it started in the morns everything was sweet
But it was to all come crumbling down it lasted about 2 weeks after the valves were shimmed, then one day on the way home from work she went bang! at 100km and locked up I had oil all over my back tire luckily I pulled my clutch in immediately and just rode it out to a full stop felt like a bar of soap though haha! after that happened it has sat around for 6mnths while I tried to source a new engine to no avail, so I thought bugger it ill sell it on ebay for a parts bike, until I got a message from "Kiffsta" asking me if I was interested in a spare engine he had.
I was interested and closed my auction, and up to date as of today 27-05-13 I have just stripped all the parts of my blown engine that I may need one day , magneto case, clutch, starter, carbs ect. I also found the reason for my conrod to break, my camshaft gear had spun on its pressfit and put the timing out which resulted in a bang!
Anyway hope you enjoyed my story will do more updates after I install my new engine that i'm yet to receive.
Last thing I'd just like to say a big thanks to "kiffsta" for hooking me up, much appreciated.
Bye guys!

 

my mid stage when I had it painted regod running

 

And what I did 27-05-13 removing and stripping the parts off the blown motor

 

Cheers! Im hoping so haha

 

Hi Phill, yeah the bang wasn't fun at all pretty sketchy haha! yes it's very good praying the new donk will be a cracker! and will be uploadlng more pics once I have purchased-received the new motor. cheers Dan

 

Update new motor is on its way woohoo

 

Hi guys just wondering if someone can give me the part no. of the oil filter?

 

Hi everyone update coming soon havnt had much time to work on the motor but I have fitted it and found the timing chain was a tooth off. I relised this when I first ran the bike and saw the no.2 carby was igniting meaning the valve was leaking or in my case timing chain was installed incorrectly. Ps them auto timing chain tensioners are a bitch lol. Anyway its running, idleing smooth just not reving out past 8k pretty sure its a fuel issue going to adjust floats as soon as I have some free time. Will let everyone know how it goes and upload some pics shortly. Cheers dan

 

oh right update time, so when I assumed my 8k reving issue was fuel I was mistaken, and in fact I didn't only have one leaking valve I had two when compression testing some times compression would totally disappear which was very funny so the only thing to do was pull the motor back out again and pull it down that's when I found two intake valves on 1&3 to be sitting up the retainer had jumped out because the stem was shawn apart and holding the valve open it must have been jumping in and out giving me compression sometimes then totally nothing others, there was a new chain installed in the motor when I received it so I assume the chains slipped and broke these valves someone has fitted new chain ( which was incorrect and one tooth out) and hoped it was okay but it was not, heres some pics to help you understand easier it may be a bit hard to follow.

 

I've salvage the best 2 intake valves from my blown motor and seated them in, fitted new rings, and head gasket, I chucked it all together yesterday 27-07-13 and fitted the motor this morn, and finally some results! idles, revs and sounds amazing again. so ill just have to keep testing it out daily but I think shes a goer heres some more pics of the rebuild. just got to keep testing it regulary to make sure shes sweet then back on the road =)

 

Thanks alot man. Feels good to finally have a win after all the drama

 

Ebay $38 for set of rings $50 head gasket. I acctually called a moto shop In brissy $51 each piston for rings $60head gasket $450 just for set of intake valves.

 

Thanks phil